The 10 biggest car recalls of all time

Toyota Motor Corp.
TM, +0.90%
recently surpassed General Motors as the world’s leading auto manufacturer, reclaiming a title it lost to the American car maker in 2011 following a series of huge recalls that tarnished the public’s perception of the manufacturer. Toyota’s triumph may be short-lived, however. Recently, the company announced the recall of 1.3 million cars due to a risk of air bags deploying without warning. Based on data collected from the NHTSA’s recall database, 24/7 Wall St. identified the 10 biggest car recalls of all time.

Lothar Spurzem/Wikipedia

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10. Volkswagen (1972)

Vehicles affected: 3.7 million (tied-ninth highest)

Issue: Wiper screw coming loose

Components affected: windshield wiper

In 1972, a recall was issued for Volkswagen
VLKAY, -0.07%
vehicles from the 1949 through 1969 model years. According to the NHTSA, the screw securing a car’s windshield wipers could be loosened, causing drivers to struggle to see the road during rain storms and snowy conditions. Before issuing a public announcement, the NHTSA had received complaints from more than 70 Volkswagen owners. However, according to a 1973 United Press International article, “Volkswagen decided the problem wasn't safety related and that owners should pay for repairs.”

Yasu/Wikipedia

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9. Honda (1995)

Vehicles affected: 3.7 million (tied-ninth highest)

Issue: Belt buckle release breaking

Components affected: seat belt buckle assembly

Honda Motor Co.
HMC, +7.30%
was forced to recall 3.7 million cars in the mid-nineties due to a defective seat belt buckle assembly. This recall affected the Accord, Prelude and Civic models from the 1986 through 1991 model years. A number of models from Honda’s Acura line were also impacted. The seat belt release button In the recalled cars had the potential to break—a problem the NHTSA determined “worsens with time and exposure, creating a greater risk of buckle failures as time goes by.” In all, numerous Asian and American car makers were hit by recalls for the seat belts, which were made by Takata Corp., but none was more affected than Honda.

Joost J. Bakker/Wikipedia

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8. General Motors (1973)

Vehicles affected: 3.7 million

Issue: Stones entering engine compartment

Components affected: underbody shields

More than 3.7 million General Motors vehicles from the Buick, Chevrolet, Oldsmobile and Pontiac lines were recalled in 1973. The problem: stones from graveled and unpaved roads could become stuck in the engine compartment, potentially affecting the driver’s ability to steer. This was corrected by installing a gravel shield over the steering coupling. According to United Press International, the Center for Auto Safety alleged that it had alerted GM to the problem in July 1972, six months before the auto maker initiated the recall.

Oren09/Wikipedia

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7. Ford (1972)

Vehicles affected: 4.1 million

Issue: Connecting part in seat belt breaking from wear

Components affected: seat belt webbing

In 1972, Ford Motor Co.
F, -1.79%
had to recall more than four million vehicles to fix a small component: a grommet that was part of the seat belt. This could break with repeated usage, making it impossible for the driver or passenger to lock in the shoulder harness. Each grommet cost only a few cents to make, according to a June 1972 Associated Press article. The recall affected most cars produced by Ford for its U.S. lines for the 1970 and 1971 model years, excluding only its Maverick and convertible models. The problem was easily corrected by replacing the original piece with another made of neoprene.

Wikipedia

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6. Toyota (2007-2010)

Vehicles affected: 5.7 million

Issue: Floor mat interfering with accelerator pedal

Components affected: accelerator pedal

In 2007, Toyota issued a recall on the optional All-Weather Floor Mats Toyota sold for its 2007 and 2008 Camry and Lexus ES 350 (left) models. These mats could move forward while the car was in motion, causing the accelerator pedal to become stuck. In early 2009, Toyota issued a second recall, this time for the 2004 Toyota Sienna, in which the carpet cover could also become stuck and lead to unexpected acceleration. Later that year, the company recalled 4.4 million more Toyotas due to the same problem. This was expanded the next year to include another 1.1 million cars. In late December 2012, Toyota settled a consolidated lawsuit for approximately $1 billion with claimants who alleged economic loss. The first of hundreds of wrongful death or injury lawsuits was settled in mid-January. As of 2010, at least 89 deaths were found to have been potentially connected to unintended acceleration problems in Toyota cars.

Chevy Knight/Wikipedia

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5. General Motors (1981)

Vehicles affected: 5.8 million

Issue: Fracturing of bolts connecting control arm to frame

Components affected: rear suspension

In 1981, General Motors recalled 5.8 million vehicles—from Buick Regals to Chevy Malibus—due to the fracturing of bolts that connect the lower rear control and the car frame. All of the vehicles were made in the late 1970s and early 1980s. In instances where these bolts did fracture, the control arm would be dropped from the car, leading to a loss of control. The recall was prompted by reports to GM of 27 accidents resulting in 22 injuries, although none of the injuries were reported as serious. The bolts were replaced in all affected cars for no charge.

Wikipedia

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4. General Motors (1971)

Vehicles affected: 6.7 million

Issue: Separated motor mount causing engine to lift

Components affected: engine

In 1971, General Motors recalled nearly 6.7 million cars spanning the 1965 through 1970 model years. It was the largest recall in the U.S. up to that point. The defect summary explained that “a separated motor mount may allow the engine to lift” and could “momentarily increasing throttle.” GM initially stated that no problem existed. Instead, they alleged, the recall and modifications to motor mounts were intended to eliminate concerns brought on by misinformation. According to the Associated Press, consumer advocate Ralph Nader sent a personal letter to GM’s then-Chairman James Roche. In his letter, Nader referred to GM President Ed Cole’s comments that engine mount problems weren't serious as a “defiance of reason,” noting “the motor mount failure leads to serious vehicle behavior patterns including jammed accelerators and gearshifts and loss of power assist to brakes and steering.”

Wikipedia

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3. Ford (1996)

Vehicles affected: 7.9 million

Issue: Ignition switch short circuiting

Components affected: ignition

In 1996, an ignition switch with the potential to short-circuit led Ford to recall 7.9 million vehicles, ranging from Thunderbird convertibles to pickup trucks such as the F-350. This short circuit, capable of causing a fire in the steering column, required a replacement for the ignition switch in numerous Ford, Mercury and Lincoln cars from the 1988 through 1993 model years. According to a 1996 Los Angeles Times article, many of the fires “involved vehicles that were parked and had been shut off for hours. In some cases, autos caught fire in garages and damaged the owner’s home as well as the vehicle.”

Wikipedia

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2. Ford (1999-2009)

Vehicles affected: 15 million

Issue: Speed control deactivation leaking/ short circuiting

Components affected: vehicle speed control

Ford first issued a recall to address short circuiting with its speed control system in 1999. The recall noted that in three different models from 1992 and 1993 this could potentially lead to an underhood fire. Problems with speed control deactivation led to more recalls in 2005, which affected 5.2 million pickup trucks and SUVs. These were followed by more vehicle recalls in 2006 and 2007. In February 2008, according to the New York Times, the NHTSA took an “unusual step” and “issued a consumer advisory urging owners whose vehicles had not yet been fixed to have the switches disconnected immediately.” In October 2009, a seventh recall to address the problem was announced—meaning, in all, nearly 15 million vehicles from the 1992 through 2004 model years were affected.

Sthfldguy/Wikipedia

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1. Ford (1981)

Vehicles affected: 21 million

Issue: Unexpected movement after shifted into park

Components affected: gear position indicator, transmission

The largest automotive recall of all time involved 21 million Ford, Mercury and Lincoln vehicles with model years ranging from 1970 to 1980. The cause of this recall was a parking gear that could potential to fail to engage, even after the transmission was shifted to park and the indicator showed the car to be in park. However, Ford was able to avoid any obligation to repair the vehicles when it agreed to send a warning label to automatic transmission car owners. According to the Center for Auto Safety—a consumer advocacy group—as of 1980 there had been “6,000 accidents, 1,710 injuries, and 98 fatalities…directly attributable to transmission slippage.” See the full story at 24/7 Wall St.

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